Plural stage caliper controlled collator



March 30, 1965 G. A. GlssoN PLURAL STAGE CALIPER CONTROLLED COLLATOR 13 Sheets-Sheet 1 Filed Oct. 14. 1960 INVENToR. ffif A. G/so/v BY March 30, 1965 G. A. GlBsoN PLURAL STAGE CALIPER CONTROLLED COLLATOR 13 Sheets-Sheet 2 Filed Oct. 14. 1960 IN V EN TOR. 'fkci: 14. G 1a saw BY /Wfmzwfizu ATTORNEYS.

March 30, 1965 G. A. GlBsoN PLURAL STAGE CALIPER CONTROLLED GOLLATOR 15 Sheets-Sheet 3 Filed Oct. 14. 1960 Ni J , ,zfizz A TTORNE V5.

March 3o, 1965 G. A. GIBSON 3.175,821

PLURAL STAGE CALIPER CONTROLLED COLLATOR Filed Oct. 14, 1960 13 Sheets-Sheet 4 'III/'11111 INVENToR. GEORGE A. G/aso/v W/ Mask/9% TTOR'NEYS.

March 30, 1965 G. A. GlasoN 3175321 PLURAL sTAGE CALIPER coNTRoLLED coLLAToR Filed Oct. 14. 1960 13 Sheets-Sheet 5 Mvke TToRNEYs.

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March 30, 1965 e. A. GIBSON PLURAL STAGE CALIPER CONTROLLED COLLATOR 13 Sheets-Sheet 9 Filed Oct. 14, 1960 March 30, 1965 e. A. GlssoN PLURAL STAGE CALIPER CONTROLLED COLLATOR 13 Sheets-Sheet 10 Filed 001;. 14. 1960 mim.

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March 30, 1965 e. A. GIBSON PLURAL STAGE CALIPER CONTROLLED COLLATOR 13 Sheets-Sheet 11 Filed oct. 14,

IN V EN TOR. GEO/P6: A. G/oN BY W/Ww/ g *am ATTORNEYS.

March 30, 1965 G. A. GlBsoN PLURAL STAGE CALIPER CONTROLLED COLLATOR 15 Sheets-Sheet l2 Filed Oct. 14.

in IIEHIII-IIHIIHI-t INVENToR. GEORGE A /Bso/v ATTORWEYS.

March 30, 1965 G. A. GlBsoN 3175,321

PLURAL STAGE CALIPER CONTROLLED COLLATOR Filed Oct. 14. 1960 13 Sheets-Sheet 13 ...wwwwwbm 3,175,821 PLURAL STAGE CALIPER CONTROLLED COLLATOR George A. Gibson, New York, N.`Y. (165 Clymer St., Brooklyn 11, NX.) Filed Get. 14, 1960, Ser. No. 62,603 48 Claims. (Cl. 270-58) This invention relates to machines for assembling sheet articles in predetermined relationship and more particularly to means for automatically collating stock such as sheets of paper.

Presently known collatng machines provide some semblance of automaticity in their operation wherein there is an automatic assembly of sheets into collated stacks With the stacks being progressively and continuously collated during the operation of the machine. These known machines, while eifecting economies in labor and time, nevertheless require substantial supplementary manual Operations particularly in the early and terminal parts of the operation When the first and last groups of collated stacks are being formed. In addition, these machines inevitably take up a considerable amount of space and since they are frequently employed in business and commercial areas Where space is at a premium, their bulky character represents in many cases a substantial overhead expense. Many of the machines used heretofore are also notoriously unreliable, breaking down at frequent intervals and requiring constant maintenance. Moreover, those areas which require manual intervention are generally inaccessible and present difliculties and hazards to the operator. An additional defect resides in the fact that there is frequently uncertainty in the operation of .the machine to the extent that the collated stacks may contain an excess or deficiency of component sheets.

It is accordingly an object of the invention to provide collating apparatus which through a novel relationship among the mechanisms pro-vides large capacity operation in a minimum of space.

A still further object of the invention is to provide collating apparatus so instrumented as to be substantially automatic in all phases of its operation.

An additional object of the invention is to provide collating apparatus with means for insuring With virtual certainty that the correct number of sheets have been assembled.

A still further object of the invention is to provide collating means having a plurality of collating stages so interrelated in time as to produce reliable high-speed operation.

Other objects include the provision of a collator which is readily controlled by the operator, which, While rapid and certain in operation, handles the sheet material in a delicate manner so as not to mar or deform the same and which is adaptable to handle a variety of collating tasks involving different sizes and numbers of sheets.

These and other objects and advantages of the invention will be set forth in part hereinafter and in part Will be obvious herefrom, or may be learned by practice with the invention, the same being realized and attained by means of the instrumentalities and combinations pointed out in the appended claims.

Briefly and generally the invention consists of collating means comprising a plurality of sheet-issuing stages spatially and synchronously interrelated such that the stages issue sheets to a receiving means synchronized therewith to form collated stacks. The invention also includes novel caliper means for checking the operation of a sheet-issuing stage or stages, novel triggering and control means for rendering a plurality of stages and certain modes of operation thereof interdependent, and a novel nited States Patent O 3,l75,82l Patentecl Mar. 30, 1965 arrangement between impelling means associated with the receving means and the spatial Orientation of the sheet-issuing stages.

The invention consists in the novel parts, constructions,

ice

arrangements, combinations and improvements herein shown and described.

Illustrating an exemplary embodiment of the invention are the drawings. These drawings are to some extent fragmentary and to some extent schematic so that the principles of operation and significant details of construction may be clearly perceived. In addition, except for FIGURES 2, 11, 18, 19, 26 and 27, all of the drawings represent views which are orthogonal to or parallel to the plane identified as 72 in FIGURE 2.

Of the drawings:

FIGURE 1 is an elevation view partly in cross-section illustrating the collator according to the invention as seen from the front thereof with four stages illustrated;

FIGURE 1a is a continuation of the subject matter of FIGURE 1, also partly in cross-section, illustrating the output end of the collator;

FIGURE 2 is an end elevation of the collator illustrating the framework, panell-ng, certain of the drive mechanisms and the general structural layout;

FIGURE 3 is an enlarged elevation view of a section of FIGURE 1 illustrating the various means associated with each stage for causing the controlled and monitored issuance of the sheet therefrom;

FIGURE 4 is a plane view partly in section of the mechanisms of FIGURE 3, the view being taken normal to -the run of conveyor 43 in FIGURE 3;

FIGURE 5 is a Sectional view taken along the lines 5-5 of FIGURE 4 and illustrating register-img and extraction means mounted below the hopper of stages of the collator;

FIGURE 6 is an elevation view illustrating certain means for controlling the extraction of sheets at a plurality of stages as viewed from behind panel 72 of FIGURE 2 looking towards the rear of the machine;

FIGURE 7 is an enlarged elevation view partly in cross-section of a section of the subject mater of FIG- URE 6, together with additional mechanisms also op` erative in controlling extraction;

FIGURE 8 is a plan view -partly in section taken along the lines 8--8 of FIGURE 7;

FIGURE 9 is an enlarged elevation cross-Sectional view taken along the lines 9--9 of FIGURE 7;

FIGURE 10 is a perspective view of one of the operating mechanisms illustrated in FIGURE 9;

FIGURE 11 is a view taken along the lines 11-11 of FIGURE 10;

FIGURE 12 is a plan view partly in section illustrating certain power transmission mechanisms and conveyors 'of the ycollator according to the invention;

FIGURE 12a is a plan view partly in section illustrating a continuation of the subject matter shown in part in FIGURE 12;

FIGURE 12b is an end elevation view partly in section taken along the lines 12b-12b of FIGURE 12a;

FIGURE 13 is a plan view partly in section illustrating certain driven and oscillator mechanisms for providing extraction and caliper functions and mechanism for providing controlled caliper operation;

FIGURE 14 is an enlarged view taken along the lines 14--14 of FIGURE 13 and illustrating means for controlling the caliper function;

FIGURE 15 is an opposing elevation view of the subject matter of FIGURE 14 and also illustrating additional mechanisms associated with the caliper function;

FIGURE 16 is a view taken along the lines 16-16 of FIGURE 15;

FIGURE 17 is a view partly in'section taken along the lines 17-17 of FIGURE and illustrating additional mechanisms associated with the caliper function;

FIGURES 18 and 19 are perspective views illustrating elements operable in the caliper function as illustrated in FIGURES 13 to 17;

FIGURE 20 is an end elevation view partly in section taken along the lines 20-20 of FIGURE 13;

FIGURE 21 is an end elevation view partly in section taken along the lines 21-21 of FIGURE 3 and illustrating caliper disable means;

FIGURE 22 is a front elevation view partly in section of trigger function control mechanisms as seen when looking towards the rear of the machine with front panel sections 33 and 34 removed;

FIGURE 23 is an end elevation view partly in section taken along the lines 23-23 of FIGURE 22;

FIGURE 24 is an end elevation view partly in section taken along the lines 24-24 of FIGURE 22;

FIGURE 25 is an end elevation view partly in section taken along the lines 25-25 of FIGURE 3;

FIGURE 26 is a functional data flow diagram illustrat- Ving certain elements of each stage of the machine together with motor control circuit means and schematic representatons of certain intra-stage and interstage interrelationships in the collator according to the nvention; and

FIGURE 27 is a schematic illustration of exemplary intrastage Iand inter-stage timing relationships.

General characteristics As sene in FIGURES l, la, and 2, the collator according to the invention comprises a tandem array of stages each including an inclined hopper 30 at the front (right side of FIGURE 2) of the collator. Each hopper is connected to and carried on a strut 31 which is secured to and extends orthogonally outward from chassis panel 33. The lower region of each hopper also rests on a guide Vplate 40 coupled to a panel 34. Since the panels 33, 34

are inclined towards the rear of the machine (left side of FIGURE 2), the hoppers, besides being inclined longitudinally towards the output end of the collator, are also inclined towards the rear thereof as seen in FIGURE 2, and the piles of stock 35 carried thereon are accordingly urged both downward and against back walls 36 of the respective hoppers.

Extraction of sheets 37 from the stock 35 of each hopper 30 is facilitated by the operation of an extractor control roll 38 and cooperating control finger 39 both disposed at the bottom, feed end, of each hopper, so as to engage the stock 35 and in particular, the top sheet thereof. This action is facilitated by fanning the stock to form a canted pile as shown in FIGURE l. Each extrac- 'tor control roll, preferably of soft rubber, is intermittently operated in one direction (ccw. as seen in FIGURE 1) as described more fully hereinafter, and in combination with the respective control finger 39 which bears lightly against the' periphery of the roll 38, acts to extract sheets 37 from the respective stock pile 35. A system of this general arrangement is disclosed in applicant's Patent No. 2,155,s95.

' As each sheet at each stage issues from between roll 38 and finger 39, the leading edge, impelled by roll 38 and directed by the extractor guide plate 40 contacts the underside and angularly displaces a trigger finger 41 which as more fully described hereinafter, signals the passage of sheet 37 through the particular stage and initiates an extraction cycle at the next stage. As it engages trigger finger 41, the lead edge of sheet 37 is gripped between a pair of ltransfer rolls 42. The lower roll 42 is preferablyeof rubber and is driven to rotate continuously clockwise (as seen in FIGURE 1). The rolls 42 act to impel sheet 37 between an intermittently operated caliper roll 44 and a continuously driven anvil roll 44'. The caliper 44 is synchronously moved into contact with and senses the thickness of the material passing between it and the anvil roll 44; if more or less than one or some prcdetermined number of sheets 37 is present, caliper roll 44 is displaced to thereby initiate signalling actions including the generation of cut-off signals which terminate certain operations and also including the energization of signal means such as signal flag 45 at the particular malfunctioning station. These Operations will be more fully described hereinafter.

After being calipered, and assuming the correct caliper response, sheet 37 is transported on a pair of coplanar sheet conveyor belts 43 each of Which is driven by a pulley 46 in cooperation with a respective idler pulley 47. For urging sheet 37 against belts 43, a plurality of guide rolls 48 disposed along each belt 43 are provided, these being freely rotatable and gravity urged against the sheets 37 as they pass along the conveyor belts 43.

After leaving belts 43, the sheets 37 pass to receiving means including a platform 49. Disposed below the platform is a stack conveyor comprising endless chain 50 driven by sprocket 51 (FIGURE la) in combination with idler 52 and having a series of impeller fingers 53 which are carried on chain 50 and extend through a longitudinal slot in platform 49. After a sheet 37 is received by platform 49 it is engaged by an impeller 53 and impelled along the platform, passing under the succeeding Stations. As it reaches the region of the next succeeding station a sheet issues therefrom, the latter having been extracted from its respective hopper in response to either the actuation of the trigger finger 41 of the prior station as described above or by means described hereinafter. (The second and succeeding stages are instrumented similarly to the first described stage except as otherwise noted.)

To bring the stack of two sheets into registration-the later issued one having landed by virtue of machine timing in overlapping but not necessarily aligned relationship with respect to the first issued sheet (see FIGURE l) -there is provided a register finger 54, the proximal end of which is pivotally hung from the panel 34 at the third (and succeeding) stages adjacent the sheet conveyor means of the second station. The distal end of each register finger 54 lies on platform 49 and upon being contacted by the later-delivered sheet, temporarily restrains the same in a fixed position on the platform 49 until the trailing edge of this Vsheet is contacted by the stack impeller 53. At this time the sheets are in register. Register finger 54 is then displaced'away from the leading edge of the nowregistered stack due to the thrust of the impeller 53, thereby permitting the stack of sheets to be impelled to the next station.

The above-described actions are repeated as desired until the desired quantity of sheets 37 are collated. As may be seen clearly in FIGURE 1a, the sheet issuing from the final stage is brought into register with the collated sheets 37 and the completed stack is impelled to a receiver conveyor comprising a plurality of coplanar endless receiver belts 55 driven by a pulley system including drive pulley 56, idler pulley S7 and tension pulley 58. For urging the stack against receiver belts 55, there is provided for each a plurality of freely rotatable receiver guide rolls 59 rotatably mounted on the ends of respective levers 59a the other ends of which are pivoted to the frame. From the receiver conveyor, which trai/els at a higher linear speed than the stack conveyor, the collated stack may be delivered to suitable known mechanisms for stapling, stitching or the like.

Power distribution for eifecting operation of the various mechanisms will be described more fully hereinafter, it being noted here that the main motive means comprise a motor 60, FIGURE 2, mounted on an adjustable platform 61, the rear end of which is pivoted on a rear frame strut 62 and the forward end of which is eifectively threaded On a vertical Worm shaft 63 having a handle 4 secured thereto. The handle when rotated, adjusts the langular position of platform 61 and accordingly adjusts ley 66 on motor of) thus permitting adjustment of the speed at which idler pulley 67, fast on main shaft 63, ls driven. As described more fully hereinafter, several transmission means supply motive power from main shaft 68 to the various dynamic members such as the extractor, caliper, sheet conveyor, stack conveyor and receiver conveyor means.

The above-described mechanisms of the collator according to the invention, are mounted on a chassis comprising a generally rectangular base table formed of vertical struts 62, FIGURE 2, forming legs thereof, braces 69 defining the top surface thereof, these being interconnected with struts 62, and cross braces 70, also interconnecting struts 62. Mounted on and secured to the top braces 69 is a chassis structure comprising the front panel section '71, FIGURE 2, and successively above section 71, the aforementioned panel sections 34 and 33. The sections 333, 34 and 71 are coplanar and connected along configuous longitudinal edges to form a complete front panel '72 secured to the base and running the length of the machine. Various of the operating mechanisms are secured to sections 33, 34 and '71 while others are secured to the base or to lateral flanges 73, '74 and 75, the last two being respectively orthogonal to and integral with panel sections 33 and 3d. Those mechanisms Which are operativo in actually mcasuring and manipulating the stock, as well as the various controls, are oriented in front of panel 72 While the actuating means for these mechanisms are to the rear of the panel. This arrangement, in conjunction with the rearward tilt of panel 72 and the termination of various shafts and the like in journals mounted on the panel provides important accessibility. The operator may readily reach the hoppers 3%, the stack conveyor 51, the various feed mechanisms, operator controls and indicators 45, without interference from shaft supports, drive mechanisms and actuating means.

Operating characteristics It will be assumed that motor 6d is energized and running. Accordingly, the transfer rolls, 42, at each stage, FIGURE l, the sheet conveyor 43 at each stage, the common stack conveyor 50 and the receiver conveyor 55 are all placed in continuous rotary operation. The caliper rolls 44 are intermittently positioned in their sensing modes of operation. However, as explained more fully hereinafter, the extractor control roll 38 at each stage, FIGURE 1, is not operated and sheets accordingly do not issue therefrom.

With motor dt) running, an extractor start lever fell, FIGURES 1-3, 22, 23, 26 is placed in the Start position (FIG. 22), and by means more fully described hereinafter, actuation of this lever triggers the eXtractor control means of Stage No. 1, as illustrated schematically in FIGURE 26. The extractor control roll 38 of that stage accordingly commences rotation which results in the extraction of a predetermined number of sheets, e.g., one, from the associated hopper 50. This is symbolized at Stage No. 1 of FIG. 26 by the solid arrow. The sheet thus extracted, as noted hereinbefore, actuates the trigger 41 of Stage No. 1, thereafter passing through the caliper means, etc., to the stack conveyor 50. The actuation of trigger 41 causes, in turn, actuation of control mechanism for the transmission of a control signal to the extractor control means of Stage No. 2. See FIGURE 26. The extractor roll 33 at this stage is accordingly actuated in similar manner to the corresponding control roll of Stage No. 1, whereby a sheet is extracted from the hopper Sil of Stage No. 2 and, after transition through the associated trigger 41, the transfer rolls 42, caliper 44, etc., is stacked on the prior issued sheet of Stage No. 1. The relative timing of the extraction functions of each stage is controlled, as later described, such that the sheet of Stage No. 2 is not extracted until a predetermined interval after the extraction of the associated sheet of Stage No. 1, whereby, with a coordinated timing of the stack conveyor, the sheet of Stage No. 2 is delivered in overlapping relationship to the complementary Stage No. 1 sheet.

The extraction of a sheet from Stage No. 2 causes a triggering of Stage No. 3 in the manner above described, Whereby a third sheet from the latter stage is added to the stack being formed on the stack conveyor. This action continues in progressive fashion until sheets have been delivered to the stack from all stages to complete the same. While this is occurring, new stacks are being concurrently formed, since Stage No. 1, being continuously triggered by lever 169, continues repetitively to issue sheets, thus triggering sheets from the subsequent stages; all this occurs While the first stack is receiving sheets from the later stages.

By providing the triggering function described above, the stages issue sheets continuously and progressively so that the formation of incomplete stacks at the beginning and end of the collating operation is avoided. This may be contrasted with prior arrangements in which all of the stages issue sheets simultaneously and the operator is required to discard or manually complete the first and last group of stacks.

The triggering function may be disadvantageous at times other than the beginning and end of the collating operation and means described below are accordingly provided for by-passing the triggering function. It may also be noted that the triggering feature to some extent has a caliper function in that it acts to prevent the issuance of a sheet from a succeeding stage When a sheet fails to be extracted from the preceding stage. However, this function is also provided by the Operations of other means described below and hence the triggering function may be properly by-passed during certain periods of the collating process as will become clearer from the description below.

ln the sourse of issuing `from each stage, the extracted sheets, las noted hereinbefore, are subjected to caliper means to determine whether the proper number of sheets has been extracted. 'This action is schernatically indicated in FIG. 26. Thus, after `a sheet passes trigger 41 and between transfer rolls 42, the caliper roll 44 is moved by caliper control means, described hereinafter, into a sensing position Wherein the number of extracted sheets is sensed or detected. If the number is correct, there is no change in the collating operation. If the number is incorrect, then means responsive to the caliper means 44 are -activ-ated resulting in two signalling actions: first, `an indication at the nral-functoning stage is provided (FIG. 26) conveniently in the form of the signal flag 45 which is forwardly displaced to thereby identify the malfunctioning stage. At substantially the same time, the armature 161 of a normally closed microswitch 162, FIGURES 13, 20, 26, is actuated to open the circuit to motor 6G and stop the same. The collating operation is accordingly termina-ted.

For the sake of illustration it Will be yassumed that the :above-described malfunction occurred at Stage No. 2 in the middle of the collating operation and took form in the failure to provide extraction of a sheet. This failure Would terminate the triggering action a-t Stage No. 3. Moreover, the caliper means at Stage No. 2, detecting no sheet, would cause the collator to stop. Assuming further tha-t 'the operator manually replaced the missing sheet, the collating operation could then -be restarted. However, in view of the triggering function described above, Stage No. 3 Would not now issue a sheet because the failure at Stage No. 2 prevented the triggering of Stage No. 3. Similarly, Stages 4, 5 would be Without their respective triggers. But as noted above, after the first stack has been collated, all of the stages will be repetitively issuing sheets; pa-rtially completed stacks exist yat all of the various receiving points along the stack conveyor Sil. Thus, after the machine is started again one of ythe incompleto stacks at Stages 3, 4, 5 along the conveyor arrasar will not receive the required additional sheets `and incomplete stacks will result.

To prevent this condition trigger by-pass means, FIG. 26, described hereinafter, are provided Which are automatically actuated by the trigger means 41 at the last stage of the chain, FIGURES 1 and 26. Thus after the first stack is collated, there is provided a continuous triggering of the stages independently of the issuance of sheets from the preceding stages. Thus, the various stages will eject sheets after the collator is again started without Vawa'iting the transmission of a trigger signal, thereby cornpleting the partially formed stocks present on the collator. Since cxtractor oscillator means, such as schematically shown in FIGURE 26 and described hereinafter, are provided for synchronously pulsing all of the stages, and since these oscillator means are coordinated in time With caliper oscillat'ing means which synchronously pulse the caliper means at each stage and since both these oscilla-tor means are sync'hronized in turn with the various transfer and conveyor means including the stack conveyor, then the collating operation will continue in correct fashion notwithstanding the trigger function is bypassed.

After the last desired sheet issues from the hopper 3%) of Stage No. 1, the Start lever 160 is returned lto the Stop position whereby Stage No. 1 loses its activation. At the same time, the trigger function is artomatically restored and since no sheet issues subsequently from Stage No. 1, the succeeding stages, lacking trigger signals, will progressively stop after they deliver their respective sheets to the last-collated stack.

When it is desired to use less than the full capacity of the machine, the runused Stage Nos. 1, 2 etc., may be simply deactivated. This is accomplished by actuating caliper disable means FIG. 26 at the deactivated stage or stages, each of these disable means being operated by a respective caliper disable lever 164, FIGURES 1, 3, 21 and 26. This operation prevents the caliper means at the unused stage from tripping the automatic cut-off mechanism including microswi'tch 162, which would otherwise result since no sheets are issuing therefrom. In addition, the previously described Start lever 160 is left in its Stop position and instead, a lever, 16h' (Start No. 2, Start No. 3, etc.) FIGURES l, 3, 26 is actuated at the first stage to be used. The procedure described for operation at full capacity is then followed.

Power distribution The operation of motor 66 is initiatcd, as illustrated in the circuit of FIGURE 26, by pressing normally-open start switch S1 whereby a circuit is momentarily comp'ieted from electrical source terminal P1 through the normally closed contacts 161 of cut-off switch 162, through the now-*bridged contacts of switch S1 and Ithe normally closed contacts of a stop switch S2, to the field of a relay R. The other relay terminal is returned to the power terminal S2 as indicated by the ground symbols.

Energization of relay R results in closure of relay contact pairs C1 and C2, the latter completing a circuit from power terminal P1 to motor 60, Vand the former acting as a holding circuit which shunts start switch S1 to maintain relay R energized after start button S1 is released. The motor 60 is thus energized.

Automatic stopping of the motor is accomplished by the switch 162 which when opened in response to a malfunction, acts to open the relay circuit thereby deenergizing motor 60. This automatic cut-off action may be 'oypassed during certain modes of operation by operating normally open switch S3. When closed, this switch shunts cut-off switch 162. For manually stopping the collating action stop switch S2 is opened.

Operation of motor 66 drives main shaft 68, FIGURE 2, as hereinbefore described. Shaft 68 extends the length of the apparatus as seen in FIGURES 12, 12a and 1212, the ends Ithereof being journaled in hearing 31, on plate 8 '73, FIGURE 2, `and hearing 32, on brace 83, FIGURE 12a; intermediate sections of shaft 68 are supported as by lhearing 34 on brace 85, FIGURE 12a.

Driven by main shaft 68 is a branch shaft 86, FIG- URE 12, via a sprocket 87 fast on shaft 68 near the distal end thereof, a chain 88, FIGURES 12, 12h, and a driven sprocket 89 fast on one end of shaft S6. The branch shaft is journaled in a hearing 90 mounted on ilange 74, and also in gear housing 91 provided at each stage along shaft 86.

Fixed on shaft 8o at a plurality of intermediate points are helical ge'ars 93, FIGURE 12, one allocated to each stage of the machine `and located in the respective housin g 91, Driven by each gear 93 is a gear 94 fixed on one end of a respective transverse shaft 95 which is journaled in a bearing 96 secured to panel section 34. Fast midway on shaft 95 is a gear 97 which through idier gear 98 drives a gear w fixed on a shaft 1116. 'This arrangement may also 'oe seen in FIGURE 3. Each shaft 109 carries the sheet conveyor drive pulleys 46 which drive the respective sheet conveyor belts 43. Accordingiy, the sheet conveyor means are continuously driven by the above-described transmission `from main shaft 63.

The shaft 95 which `carrics gear 97 also carries at its forward end two of the transfer rolls 42, described hereinbefore. The inner of these rolls cooperates with the contiguous upper roll 42, free on a shaft 162, FGURE 3, to transfer sheets 37 from `the extractor means 33, 39 to the sheet conveyor means 43, 46, 47 and 43.

Fixed on main shaft 63 near the distal end thereof is a helical gear 163, FIGURE 12a, which engages a driven helical gear 104; fixed on a transverse shaft 165 which is journaled in bearings 166 secured to respective braces 107. The latter are connected with braces 83, 85 to form a rigid generally rectangular support means. Fixed on shaft 1115 is gear 1113 which meshes with a driven gear 1599 on another transverse shaft 116. At one end and at an intermediate position, shaft 111) is journaled in bearings 111 and 112. The other end of the shaft extends forwardiy of front panel 71 and carries the drive sprocket 51 of the stack conveyor chain 56. The stack conveyor is thus also continuously driven from main shaft 63.

The receiver conveyor is also driven continuously from main shaft 68. This is accomplished by a transmission which includes a helical gear 113 fixed on shaft 68 which drives a gear 114 fixed on a transverse shaft 115. Shaft 115 is journaled in bearings 116 secured to the respective braces 107. A gear 117 is secured to shaft 115 and meshes with a driven gear 113 fast on a shaft 12d. The latter is journaled at an end and at an intermediate position in bearings 1211 also on the respective braces 107. The other end of shaft 1211 extends forwardly of panel section 71 and has fixed thereto the receiver conveyor pulley 56 which drives the receiver belts 55. The idler pulley 57 of the conveyor is fixed on a transverse shaft 122 journaled in bearings 123 mounted respectively on panel section 71 and a parallel rearwardly displaced panel 71a (see alscI FIGURE 2). By this arrangement, the receiver conveyor is also continuously driven from main shaft 68.

Power distribution for energizing the caliper and exractor functions include a gear 131 fast on main shaft 68 near the proximal end thereof, FIGURE 2, which gear drives helical gear 132 fast on One end of a shaft 133. The other end of shaft 133 extends forwardly of panel section 71 and has a drive sprocket 134 fixed thereto, FIGURES 1, 2. Sprocket 13d, drives a chain 135 which is tensioned by a sprocket 136 rotatable on the end of an adjustable lever 137, the other end of which is clamped in desired angular position on a pin 138 on panel 71. Chain 135 drives in turn a sprocket 139 fast on a shaft 146 journaled in a hearing 141 mounted on panel section 34-, FIGURES 2, 13. Shaft 14d has fixed to its other end caliper osciliator means including a crank 142, FIG- URES 6, 13, the eccentric end of which is loosely coupled air/'5,821

to a pitrnan rod 143. Rod 143 is loosely coupled to caliper drive bar 145, which. bar reciprocates in response to rotary motion of shaft 14%. The caliper drive bar 145 is accordingly reciprocally driven ultimately from main shaft 68. As will be described more fully hereinafter, bar 145 actuates means such as illustrated in FIGURES 13`-16 which are operative to control the caliper function at each stage.

A part of the above-described transmission actuated by main shaft 63 is also operative to transmit drive power to actuate extractor oscillator means for energizing extractor control means. Thus power is transferred from shaft 149, FIGURES 1, 6, 13, to a shaft 146 via meshing gears 147 and 148 fast on these respective shafts. Shafts 146 is journaled in bearings 149 and 151 on panel section 34 and fiange 74, respectively. Fixed to the distal end of shaft 146 are extractor oscillator means including a crank 153, the eccentric end of Which is rotatably coupled to pitrnan rod 154. (See FIGURES 2, 6, 13.) The other end of rod 154 is loosely coupled to extractor drive bar 155, which bar accordingly reciprocates in response to drive power from main shaft 68 via the transmission ahove described. Extractor drive bar 15 actuates in turn means such as illustrated in FIGURES 6, 7 and described more fully hereinafter for controlling the extractor roll 38 at each stage. As is evident in the drawings, particularly FIGURE 6, the extractor drive bar and the caliper drive bar 145 oscillate at the same frequency but are phase displaced.

ln summary, transmission means from main shaft 68 driven by motor 60, are provided for continuously driving the:

(l) Sheet conveyor (2) Transfer rolls (3) Stack conveyor (4) Receiver conveyor and for actuating respectively the:

(5) Caliper oscillator means (6) Extractor oscillator means The means for etfecting the extractor function and the control thereof are illustrated in FIGURES 3 to 11. Thus as illustrated therein, extractor control roll 38 is mounted on an annular rim 17th which is fixed to a shaft 171 as by a set screw 179o, FIGURES 3, 4, 8 and 9. As is evident in FIGURE 4, the extractor roll 38 and the adjacent transfer and caliper mechanisms are all located in proximity with panel section 34 of the main panel 72. and accordingly contact the marvin of the sheets 37 thereby avoiding interference with printing matter on the sheets and also enhancing the feature of accessibility mentioned hereinbefore.

Fixed on the forward end of shaft 171 is another control roll 172 which cooperates with the extractor control roll 33 in the extraction of sheets from the respective hopper. The shaft 171 also has fixed thereto a guide collar 17d, FIGURES 4, 8, 9, secured to the shaft by means such as set screw 175. Shaft 171 is rnounted in turn in a hearing Sleeve 173, the forward end of which abuts guide collar 174. Bearing 173 is mounted in turn in journal block 176, FIGURES 8, 9, which is secured to panel 34 by means such as mounting screws 177. At its rear end, shaft 171 is provided with another guide collar 18h fixed to the shaft as by means of set screw 181. Rotatably mounted on shaft 171 and abutting locking collar 18d is a roller 133. Forward of roller 183 and rotatably mounted on shaft 171 is a drive disk 185 having a hub section 135o, FIGURE 9, coaxial with shaft 171. Keyed to drive disk 185 and mounted on hub section 185o is a pinion gear 182.

For driving disk 15 via pinion gear 182. there is provided a rack 295 which is secured to a yoke 206. The

yoke 2116 reciprocates in turn on the roller 183. Pivotally connected to the handle portion of yoke 296 is a trans- Verse bracket 298. The other end of bracket 2118 is connected in turn to reciprocating bar by means of screws 211). It will be recalled that reciprocating bar 155 cornprises the output member of the extractor oscillator means which include link 15d connected to bar 155 by pivot pin 211, Crank 153, etc (see FIGURE 6). For guiding bar 155 in its reciprocal motion, brackets 2,12 fixed at one end to panel 7d and carrying guide rollcrs 213 at their distal ends are provided. The guide rollers 213 extend in turn into slots 214 in bar 155 and serve to guide the movement thereof.

The drive disc 185, driven by oscillator bar 155 as aforesaid, is in friction engagement at its front face with control disc 186, FIGURES 6-12, having a fiange section 137 which mates with an annular groove 188 in drive disc for providing alignment. Frictional engagement of the two discs is ladjusted by means of a pair of screws 19d which pass through slots 131 in control disc 136 and into threaded engagement With drive disc 185 (see FIGURE ll). Spring loading of screws 19h is accomplished by means of Springs 193 on the shanks thereof.

Pivoted on a pin 194, FIGURE 7, extending longitudinally from the front face of drive disc 185 is a pawl 195, FIGURES 7-9. This pawl is urged radially inward by means of spring 196, one end of which is connected to a post on the pawl and the other end of which is connected to a post fixed on drive disc 185. The pawl 195 is carried on the face of drive disc 185 at a point adjacent a region Zilda of control disc 186. In this region 2119111:, a r egrnent of disc 136 is cut away leaving an arcuate surface on which the engagement end of pawl 195 can ride. This arcuate surface in one segment is cut away leaving a slot 2110, FIGURE 10, which provides access to the center section of the control disc.

Fixed coaxially on shaft 171 in the central area defined by the inner periphery of the control disc is a ratchet 2tl1, FGURES 7, 9. Since the ratchet 201 is keyed or other- Wise secured to the shaft 171, then rotation of the former Will cause a corresponding rotation of the extractor control roll 33 fixed on shaft 171. Whether ratchet 201 and the extractor control roll are rotated or maintained stationary, depends in part on whether pawl 195 is in engagement with the ratchet. If the pawl carried on drive disk 185 is in a position relative to control disk 186, such that the pawl under the urging of spring 196 gains access to ratchet 201 through slot Zilil in the control disc, then it is possible for ratchet 201 to be driven from drive disc 135 via the pawl. If the pawl does not gain access to ratchct 291, but is rather confined to the region Ztltlb of control disc 186, then ratchet 2111 Will not be driven. The two possible conditions described above are illustrated in FIGURE 7 with the pawl 195 in engagement with ratchet 291 at Stage No. l and out of engagement at Stage No. 2. Additional qualifications to the above described action will be described below.

It may be seen from the above that oscillation of bar 155 produces like oscillation of rack 265 carried on yoke 266 and accordingly produces intermittent rotary motion of pinion 182, drive disc 185, pawl 195 and control disc 136, first in one direction and then in the other. As may be seen in FIGURES 6, 7 and 8, the rack 2115 is positioned at the top of yoke 2% at one stage and on the bottom arm of the yoke at the adjoining stage, so that the rack position alternates progressively from Stage No. l to the final stage. Accordingly, when one stage is being driven in the clockwise direction, the adjacent stages are being driven in the counterclockwise direction.

As seen in FIGURES 8 and 9, a split ring 215 is clamped to bushing 173 by means of a screw 228 which passes through lugs on the ring 215. Pivotally mounted on the rear face of ring 215 isa pawl-like stop 216, one end of which is rotatably mounted on a pivot pin 217 longitudinally fixed to the face of ring 215. The distal end of 1 1 stop 216 is loosely coupled by means of a pin 218 to a link 219, and the opposite end of this link is connected to one end of a transverse stud 2?` by means of a pivot 226.

The other end of stud 220 is coupled to the eccentric end of a levcr 221, the other end of the lever being fixedly connected to a shaft 222. The shaft 222 is journaled in hearing 223 and also carries guide collar 224 and the hub 225 of a member Which abuts the bearing 223. Afiixed to the opposite or forward end of shaft 222 is, in the case of the trigger for Stage No. 1, the start lever 160. Por the other stages, the trigger finger 41 and the respect1ve intermediate start control 160' (Start No. 2, Start No. 3, etc.) is affixed thereto. Thus, when start lever 1h19 (or 160') or trigger finger 41, is rotated counterclockwrse as seen in FIGURES l and 3, the link 219 as seen in FI G- URE 7, will be displaced to the left, at their respectivo stage thus rotating the associated stop 216 clockwise. If, on the other hand, the start lever 160 is in the Stop position, or the trigger finger at the particular stage is not displaced, then stop 216 will be in its extreme counter clockwise position. In this connection, see also FIG- URE 22.

ln addition to the stop 216, another stop is provided as described below.

Mounted on bushing 173 adjacent, and just forward of ring 215, is a split ring 230 which is clarnped on the bearing by means of a screw 233. Extending from ring 230 is a radial projection 234, FIGURE 8, fixed to Which and extending rearwardly therefrom is a stop 235. This stop and the stop 215 described above cooperate with a projecton 236 on control disc 186 as described below.

As bar 155 reciprocates, the drive disc 185 at each stage rotates reciprocally as described above. Control disc 186 will rotate in synchronism therewith since it is in friction engagement with the disc 135. Assuming that start lever 160 is in the Stop position or trigger finger 41 at the other stages is not actuated, then the free end of stop 216 will lie in the path traced by lug 236 on control disc 186. Assuming now that the drive and control discs are traveling in the counterclockwise direction as seen in FIGURE 7, and assuming further that the relative positions of the two discs are such that pawl 195 is riding on lip 200b of the control disc as illustrated at Stage No. 2 (right side) in FIGURE 7, then as the counterclockwise limit of rotation is approached, lug 236 engages stop 235 whereby control disc 186 is stopped while drive disc 185 continues counterclockwise through an additional angle. The dimensions of the system are such that this relative slippage between the two disos causes pawl 195 to pass through slot 200 into engagement with ratchet 201. This occurs during the interval when drive disc 185 ceases counterclockwise movement and commences clockwise movement.

Considering now the clockwise rotation, it may be seen that although pawl 195 is in engagement with ratchet 201, no drive action to the ratchct occurs because the pawl is rotating in the direction of ratchet pitch. Clockwise rotation accordingly corresponds with the normally stationary non-feed time interval of the extractor control roll. As discs 185 and 186 approach the clockwise limit, the lug 236 engages stop 216 causing disc 186 to stop, while drive disc 185 continues to rotate clockwise, thereby carrying pawl 195 up on lip 2001) and out of engagement with ratchet 201. As the discs now commence counterclock- Wise rotation, no drive action occurs since pawl 195 does not contact the ratchet. Under the assumed conditions then, the shaft 171 remains stationary and the extractor control roll also remains .stationary whereby no sheet issues from the stage. It may be seen from the above that When both stops 216 and 235 are contacted, no drive occurs. Further, stop 235 is contacted once every cycle and automatically resets the extractor control means in preparation for extraction which Will occur at the end of the idling stroke if stop 216 is iuoperative by reason of actuation of start lever 160 on trigger finger 41.

If now the start lever for Stage No. l or a trigger finger 41 at any of the other stages (except the last) is displaced counterclockwise as seen in FIGURES 1 and 7, then during the non-feeding clockwise stroke, lug 236 fails to engage stop 216 since the latter is now displaced clock- Wise by the action of the start lever or trigger. Accordingly, pawl remains in engagement with ratchet 201 so that on the opposite or counterclockwise stroke, ratchet 201 is driven counterclockwise thereby driving the eX- trator control roll 38. This pulsating action will occur repetitively so long as triggering exists and energization is provided by bar 155. Insofar as inter-stage timing is concerned, it may be seen that during the feed or extraction interval of one stage, the adjoining stages are in their nonfeed or quiescent condition. The interval between the extraction and quiescent conditions is adjusted to enable a sheet extracted from a preceding stage to approach the succeeding stage.

It is evident from the above that whether a particular stage extracts a sheet from its respective hopper depends on the actuation of the trigger finger 41 of the prior stage or, in the case of Stage No. 1, on the placing of start lever hi0 in the Start position.

It may also be observed that once a stage has been triggered and the collating operation put in process, there is no relative movement between the friction discs 185, 186. This reduces the tendency otherwise prevalent for wear of the discs and a consequent need to continually adjust and periodically replace them.

The means for providing the trigger by-pass function and for providing the extraction operation at less than full capacity are also illustrated in the above mentioned figures and in FIGURES 22-25. As seen therein there is provided a longitudinally extending shaft 241 journaled at intermediate points in bearings 242 secured to the panel '75. Depending from shaft 241 are transverse pins 244, one allocated to each stage and lying adjacent the respective stud 220 at each stage. Movement of shaft 241 to the left, as seen in FIGURES l, 3, 8 and 22, causes each stud 220 at the respective stage to be displaced to the left bringing the respective stop 216 out of range of the associated lug 236 whereby each stage provides synchronized extraction independent of the triggering function. Shaft 241 is urged to the left as shown for example in FIGURE 22, by means including a Weight 470 adjustably fixed to a pin 471 as by a set screW 472. Pin 4171 depends angularly from a connector 473 adjustably clamped on a shaft 474. Shaft 4-74 is rotatably mounted in an inverted U-shaped bracket 475 Which is fixed to flange 75. The weight of member 470 tends to urge shaft 241 to the left as seen in FIGURE 22 by virtue of a connection from member 473 to the shaft Which includes a yoke 478 fixed to member 473 and a collar 479 fast on shaft 241. The yoke 478 is coupled to the collar by virtue of the engagement of the distal ends thereof With a groove in the collar.

Prior to the start of Vthe eollating operation, shaft 241 is controllably maintained in the position shown in FIG- URE 22 by looking means including a collar 480, FIG- URE 22, fast on the shaft which is engaged by a catch 431 at an intermediate point on a lever 482. One end of lever 482 is pivotally coupled to a bracket 484 secured to flange 75, while its other end is pivotally coupled to a link 485. The other end of link 485 is pivotally coupled in turn to a crank 221' the opposite end of Which carries a shaft 222' to which is connected trigger finger 41 of the last stage. Lever 482 is urged upwardly as seen in FIG- URE 2,2 by engagement with a spring 488, the opposite end of which is connected to the frame by means of a strut 490. Thus, as long as catch l engages collar 80, shaft 241 is looked in position.

When control lever 160 is moved to the Start position as illustrated by the broken lines in FIGURE 22, an extraction occurs at Stage No. 1 and in accordance with the triggering function, sheets subsequently issue progressively from the succeeding stages. When a sheet finally issues 13 from the last stage, portending the complete collation of the first stack, trigger 41 at this stage is displaced to the right (referenced to FIGURE 22). This trigger action brings catch 431 out of engagement with collar 480 whereby shaft 241 is urged to the left under the influence of Weight 470. As noted above, displacement of Shaft 241 to the left moves the stops 216 at each stage clockwise via the respective studs 220 and linkages 219 whereby the extraction means of all of the stages are now continuously triggered or activated and the previously described progressive trigger function is by-passed.

When it is desired to stop the collating action, Start lever 160 is moved to the Stop position as shown in the solid lines in FIGURE 22. By virtue of Ithe coupling bctWeen lever 1.66 and the Shaft 241, the latter is displaced to the right against the action of weight 471) thereby restoring the progressive trigger function. To hold the shaft 241 in this position before it is permanently engaged by the looking mechanism associated with the last trigger finger 41, there is provided a detent mechanism on the Shaft 222 which carries the lever 160. This detent mechanism includes an arm 492, FIGURES 22, 23, fast on the Shaft 222 which arm carries a spring blade 493. Connected to blade 493 is a pin 494 Which is urged by the action of the spring into a detent hole 495 on a bracket 496. The bracket is secured to panel section 34 while the detent hole is located in the bracket in a position corresponding With the Stop position of lever 160. Accordingly, when the lever is moved to this position, it and shaft 241 are held there by the detent mechanism described above. After the last sheet issues from the last stage, trigger finger 41 returns permanently to the position shown in FIGURE 22 whereby latch 481 engages collar 480 to hold shaft 241 to the right (as shown in FIGURE 22) so that a subsequent starting of the collator will not release Shaft 241 until a new stack has been collated.

In addition to the automatic control of the triggering function as described above, manual control is provided by operating rod 163 which is fast on shaft 241. Movement of this rod to the left causes a by-passing of the triggering function as described above. For such manual operation, catch 481 must be released from collar 431) and the detent of the Start lever 166 must be released.

As was noted hereinbefore, a control 16h' is provided at the second, third and remaining stages except for the last stage. This control 166', as seen in FGURE 25, comprises an extension 501) of the member 225 fixed to shaft 222 of the respective stage. At its distal end extension 500 has afiixed thereto a boss 561 which coaxially houses a sliding pin 592 Which is connected at one end to a knob 503. Depression of knob 503 forces pin 562 against a bracket 505 aifixed to panel section 33, and, with the Start lever 160' in its Stop position, the pin engages a recess in the bracket to provide detent action.

Angular displacement of extension 50th to the left causes a corresponding counterclockwise rotation of the associated trigger finger 41, thereby initiating a triggering action at the next succeeding stage. Concurrently, a clearance between pins 244 on Shaft 241 and the studs 220 at each operative stage is provided. Shaft 241 as described above, is accordingly free to move to the left, ie., to the trigger by-pass position, after the trigger finger at the last stage has been triggered. When stopping the collating action at an intermediate stage, the control lever 160' thcreof is moved to the right, thus moving the associated trigger finger 41 clockwise and moving the shaft 241 to the right. The shaft is held in this position until permanently engaged by the locking mechanism of the last stage trigger, by means of the detent mechanism provided With each intermediate Start lever 160' as described above.

Complementing the operation of the extractor control roll 33 at each stage is the aforementioned control finger covered by a hard rubber sheath which is in contact With control roll 38, these being contacted in turn by the fanned out pile of stock 35. Finger 39 is pivoted on a shaft 251 secured to panel 34 as by a nut 25111, FIGURE 5. A coaxial hub 252 on shaft 251 is intenposed between panel 34 and a step on the shaft. The shaft 251 also serves as a support for guide plate 40. See FIGURES 3, 4 and 5. For adjusting the angular position of finger 39 and thus its relationship to extractor roll 38, means are provided including a cam 255 fast on a shaft 256, the cam abutting a bearing 253 in which shaft 256 is journaled. The distal end of the shaft has fixed thereto adjustment knob 266 while its opposite end, behind panel 34, is coupled to a friction plate 261 which engages a coaxial friction plate 26101. Plate 261 is angularly looked on Shaft 25o but free to move longitudinally by means of a slot and key arrangement 263. A threaded integral extension 262 of Shaft 2.56 is provided with a nut 265. A spring 266 coaxial on extension 262 is in engagement with nut 265 and with plate 261 via Washer 267 whereby plate 261 may be adjustably urged against plate 26151 to provide Optimum friction therebetween, thus maintaining cam 255 in a fixed position after it is adjusted by knob 260 to provide the desired sheet extraction friction between control finger 39 and control roll 38.

Calper and control The means operative to effect the caliper function at each stage together With the signal and cut-off means responsive thereto as illustrated in FIGURES 1-4 and 13-22. Thus, as seen in FIGURES 3, 4 and '15, caliper 44 at each stage is mounted for unrestrained rotation on the eccentric end of a crank 302. The other end of crank 302 is fixed to the reduced section of a Shaft 3133 journaled in a sleeve 364 of a hearing 305 secured to the panel 34. The shaft 3413 extends rearwardly of the bearing and carries connecting block 307, the block being adjustably secured to the Shaft by means of set screw 393. Fixed in a transverse slot in block 3117 is one end of a transverse follower 310. Screws 311 secure the follower to the block. lt may be seen from the above that as follower 310 is displaced clockwise as seen in FIGURE 15, there is a corresponding clockwise rotation of block 3137, shaft 393 and crank 3112. Clockwise rotation of crank 392 causes caliper 44 to rotate away from the anvil roll 44'. The above movements are reversed for counterclockwise movements of follower 310. Gain and sensitivity are provided in both directions of transmission by virtue of the above arrangement which includes a large ratio of the effective length of follower 3119 to the effective length ofrnernber 3112. In the exemplary embodirnent this ratio lies between 3 and 4, thereby providing a gain of between 9 and 16.

Extending transversely of the follower 310, near the distal end thereof, is a follower pin 312. During certain phases of machine timing, pin 312 rides on surfaccs of a control cam 313 which comprises an integral extension of a connecting plate 314. As seen in FIGURE 15, one connecting plate 314 serves two adjoining stages since each plate carries two oppositely directed control cams 313, one for each stage of the pair. By means of screws 315, plate 314 connects to reciprocating bar Which it may be recalled comprises the output member of the caliper oscillator means described herebefore (see FIG- URE 26). For guiding and supporting bar 145 means are provided including, at a plurality of points along the bar, a roller 329 extending transversely into a longitudinal slot 321 in the bar, the roller being free on an axle 322 which is secured in turn to an upstanding bracket 323 by rneans of a screw 324. The bracket 323 is connected in turn to the panel section 74 by means of screws `125.

As is evident in the iigures, reciprocation of bar 145 produces oscillatory movement of connecting plate 314 and the two control cams 313 thereof. Movements of the cams (relative to their respective pins 312 on followers 391%) are phasetdisplaced one from the other by 

1. COLLATING APPARATUS COMPRISING A PLURALITY OF SHEETFEEDING STAGES AND MEANS FOR RECEIVING THE SHEETS ISSUING FROM SAIS STAGES, A FIRST ONE OF SAID STAGES HAVING EXTRACTION MEANS AND INCLUDING TRIGGER MEANS RESPONSIVE TO THE FEEDING OF A SHEET THROUGH SAID FIRST STAGE AND A SECOND OF SAID STAGES INCLUDING EXTRACTION MEANS INTERCONNECTED WITH AND RESPONSIVE TO SAID TRIGGER MEANS OF SAID FIRST STAGE 